forno bravo, llc calore2g series modular fireplace kit, including › pdf ›...

Forno Bravo, LLC

Calore2G Series Modular Fireplace Kit, Including:Calore2G75 (SKUCC2G75)

Calore2G90 (SKUCC2G90)



Assembly and Operation Manual

OUTDOOR USE ONLY.

Forno Bravo, LLC744 Neeson RoadMarina, CA 93933

(800) [email protected]

http://www.fornobravo.com

Calore2G Modular Fireplace Kit Installation and Operation Manual

© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 1

WARNING

READ ALL INSTRUCTIONS BEFORE INSTALLING AND USING THE APPLIANCE. FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH.HOT WHILE IN OPERATION. KEEP CHILDREN, CLOTHING AND FURNITURE AWAY. CONTACT MAY CAUSE SKIN

BURNS.

ALWAYS OBTAIN THE PROPER PERMITS FROM YOUR LOCAL BUILDING AND FIRE SAFETY AUTHORITIES WHEN INSTALLING THIS PRODUCT. ALWAYS COMPLY WITH ALL LOCAL BUILDING CODES.

This product is designed to burn wood or gas. Use solid wood, or plumbed propane (LP) or Natural Gas only.

Any gas log used with this product must be approved for outdoor use.

Do not use a fireplace insert with this product.

This Product is Not Approved for Indoor Installation.

Use Only Non-Combustible Building Materials When Installing the Calore2G Fireplace,

and Follow All Relevant Building and Fireplace Codes for Setbacks to Combustibles

from the Fireplace Opening and Chimney.

SAVE THESE INSTRUCTIONS



Limited WarrantyForno Bravo, LLC Pizza Ovens and Fireplaces

THE WARRANTYForno Bravo, LLC, an importer and producer of pizza ovens

and fireplaces, warrants it ovens and fireplaces (herein

referred to as Product) to be free from defects in materials

and workmanship for a period of (1) one year from the date

of shipment.

QUALIFICATIONS TO THE WARRANTYThe complete Product Warranty outlined above does not

apply under the following circumstances:

(1) The Product was not installed in accordance with Forno

Bravo installation instructions and local building codes.

(2)The Product has been subjected to non-standard use,

including burning fuels with abnormal burning

characteristics including, driftwood, coal, plywood and wood

products using a binder that may burn at excessive

temperatures and cause damage to the Product.

(3) This Warranty does not apply to normal wear and tear.

(4) This Warranty does not apply to any cracking caused by

over-firing or the failure to follow a proper curing schedule.

(5) In the event that the Listing plate has been removed,

altered or obliterated.

(6) On parts that would be normally worn or replaced under

normal conditions.

(7) Normal cracking due to expansion and contraction

stress relief in either the dome or floor blocks.

LIMITATION ON LIABILITY

It is expressly agreed and understood that Forno Bravo's

sole obligation and purchaser's exclusive remedy under this

Warranty, under any other warranty, expressed or implied,

otherwise, shall be limited to replacement, repair, or refund,

as specified above, and such liability shall not include, and

purchaser specifically renounces any rights to recover,

special, incidental, consequential or other damages of any

kind whatsoever, including, but not limited to, injuries to

persons or damage to property, loss of profits or anticipated

profits, or loss of use of the product.

In no event shall Forno Bravo be responsible for any

incidental or consequential damages caused by defects in

its products, whether such damage occurs or is discovered

before or after replacement or repair, and whether or not

such damage is caused by Forno Bravo’s negligence.

Some states do not allow the exclusion or limitation of

incidental or consequential damages, so the above

limitation or exclusion may not apply to you. The duration of

any implied warranty with respect to this Product is limited

to the duration of the foregoing warranty. Some states do

not allow limitations on how long an implied warranty lasts,

so the above may not apply to you.

INVESTIGATION OF CLAIMS AGAINST WARRANTYForno Bravo reserves the right to investigate any and all

claims against this Warranty and to decide upon method of

settlement.

DEALERS HAVE NO AUTHORITY TO ALTER THIS WARRANTYForno Bravo's employees and dealers have no authority to

make any warranties nor to authorize any remedies in

addition to or inconsistent with those stated above.

HOW TO REGISTER A CLAIM AGAINST WARRANTY

In order for any claim under this Warranty to be valid, Forno

Bravo must be notified of the claimed defect in writing or by

telephone to Forno Bravo, 744 Neeson Road, Marina, CA,

93933. Claims against this Warranty in writing should

include the date of installation, and a description of the

defect.



Table of Contents

...........................................................................................................................................1. About Your Fireplace 5

..................................................................................................................................2. Provided with the Product 6

...........................................................................................................................................................3. Clearances 7

............................................................................................................................................................4. Ventilation 8

..............................................................................................................................................................5. Assembly 9

.............................................................................................................................6. Operation and Maintenance 11

......................................................................................................................................Appendix 1: Dimensions 12



1. About Your FireplaceThe Calore2G is a modular fireplace kit designed for

outdoor use. It consistent of a number of interlocking

refractory components that are assembled to construct the

basic fire box, fireplace throat, smoke box and chimney.

The inside of the fire box is finished with firebrick splits for

an authentic brick fireplace appearance, while the outside

of the fireplace kit can either be finished with a non-

combustible decorative materials, such as stucco, brick or

stone, or it can be built into a decorative enclosure, but

using either Concrete Masonry Units (CMU) or metal studs

and backer board.

The fireplace kit can be assembled on a concrete slab

poured at ground level, or it can be raised up with a CMU

stand and a concrete slab.



2. Provided with the Product

Part # Description 30” 36” 42” 48”

1 Base 1 1 1 1

2 Fire box back wall 1 2 2 2

3 Fire box angled back wall 1 1 1 1

4 Fire box side wall 4 6 6 6

5 Throat angled front wall 1 1 1 1

6 Throat back wall 1 1 1 1

7 Throat side wall 2 2 2 2

8 Smoke box front/back wall 2 2 2 2

9 Smoke box side walls 2 2 2 2

10 12” smoke box top 1 1

10 14” smoke box top 1 1

11 12” chimney section 4 4

11 14” chimney section 4 4

Owner Supplied Installation MaterialsHigh Temperature, waterproof mortar

Firebrick splits (9”x4.5”x1.25” or 9”x2.5”x1.25”)

Optional Owner Supplied Installation MaterialsConcrete Masonry Units (CMU)

Metal studs and backer board (Hardibacker) panels

Stucco, brick, decorative stone



3. ClearancesThe Calore2G is designed for outdoor use. It can be

installed as a free standing fireplace, or it can be built into

a larger decorative enclosure. It must be installed on a

non-combustible platform; typically a reinforce concrete

slab on the ground, or raised with Concrete Masonry Units

(CMU).

All installation building materials must be non-combustible,

such as CMUs or metal stud framing and backer board

(Hardibacker) panels. There are no air-space or clearance

requirements between the Calore2G fireplace and the

non-combustible building materials.

Do not use insulation with the Calore2G fireplace kit. In

the event that your building enclosure does have air-space

between the fireplace kit and the building materials, do not

pack insulation or any other material in the opening.

Drywall, plywood, and wood framing are all combustible

building materials and cannot be used when installing this

product.

Hearth Extension

The Calore2G fireplace kit does not provide a hearth

extension product or building material. If you want to build

a hearth extension, use non-combustible building

materials.

The minimum floor hearth extension areas from the

fireplace opening to combustible floors are as follows:

• 8” on each side of the fireplace opening• 24” in front of the fireplace opening

Additional ClearancesClearance from the fireplace opening to a combustible

sidewall is 28”

Mantel RequirementsA decorative mantel can be attached above the fireplace,

and must be a minimum of 12” above the fireplace

opening.



4. VentilationThe height of the chimney sections provided with the

Calore2G fireplace kit represent the minimum height

necessary to provide adequate air draw. Additional

chimney sections can be purchased to increase the height

of the chimney to either improve air draw and for design

reasons.

The Calore2G fireplace kit can also be vented using a pre-

fabricated, Listed UL103 steel chimney system. Available

from a number of manufacturers, these systems offer an

anchor plate, chimney pipe, spark arrestor, and various

angles and straps. Always use the correct anchor plate to

attach the chimney system to the Calore2G fireplace, and

follow the manufacturer’s installation instructions.

A UL103 Listed chimney system can be used to extend

the chimney sections provided with the Calore2G fireplace

kit, or it can be attached to the smoke box top.

Fireplace Size Chimney Diameter

Minimum Chimney

Height

30” 12” 24”

36” 12” 24”

42” 14” 24”

48” 14” 36”

Chimney termination must be a minimum of 24” above any

combustible structure within 10’.



5. AssemblyThe Calore2G fireplace kit is assembled using high

temperature, waterproof mortar. Here are some tips to

make your assembly fast and accurate.

• Take a few minutes to “dry stack” your Calore2G

fireplace kit without using mortar. That will show you

how the pieces fit together;• Know that this is a two-man job. Have a helper;• Use a level to make sure that all of your fireplace

components are level and plumb;• Be sure to calculate the thickness of the firebrick floor

and mortar to determine the finished height of the

fireplace and the height of the foundation and/or CMU

stand that holds the fireplace kit;• Use a trowel to place a 1/4” bead of mortar between

each touching fireplace component face;• Line the assembled fire box (component numbers 1,

2, 3 and 4)with firebrick splits before you assemble

the fireplace throat (component numbers 5, 6 and 7).

Assembly Steps1. Set the fireplace base.

The fireplace base (1) is not designed to span a gap

between CMU walls. If you are raising your fireplace on a

CMU stand, be sure to frame and pour a 3 1/2” rebar

reinforced concrete slab to hold the fireplace base.

Make sure the fireplace base is level and that it “faces” in

the right direction. You will not be able to move it later.

2. Set the firebox.

Mortar one level of the firebox sides (4) and back wall (2)

together and to the fireplace base. Check for level and

continue with the next level. Mortar the fire box angled

back wall (3) and the fire box sides and complete the fire

box. Check that it is level and plumb. At this point, you can

line the fire box walls and floor with firebrick splits.

3. Set the fireplace throat.

Place the angled throat front (5) and the straight throat

back (6)across the opening at the top of the fire box.

Note: the hearth extension is not provided with the

Calore2G kit.



Assembly (continued)

Place the throat side pieces (7) into the interlocking joints

with the throat front (5) and back (6).

4. Set the smoke box

Place the smoke box front and back (8) across the

fireplace throat.

Place the smoke box sides (9) into the interlocking joints

with the smoke box front and back (8).

5. Set the smoke box top

Place the smoke box top (10) over the smoke box

opening.

6. Set the chimney pieces.

Place the chimney pieces (11) over the smoke box top.

7. Line the fire box with firebrick splits.

NotesYou can enclose the Calore2G in a decorative enclosure

using CMUs or metal studs and backer board. You can

also attach non-combustible finish materials, including

stucco, brick or stone directly to the fireplace kits. You can

use brick ties with the Calore2G kit.

Do not worry if one of your fireplace components has a

hairline crack. The structure of the fireplace holds each

component tightly in place, and small cracks are not a

problem. If one of your components is cracked in one

place from improper handling, you can mortar the piece

together and continue with assembly.

If you receive a shipment which has been handled

improperly and a component is broken in more one place,

contact Forno Bravo to receive a replacement component.



6. Operation and Maintenance

Operation

DO NOT OVER FIRE

Burn solid, well seasoned wood only.

To maximize wood burning efficiency, use a log grate.

Use firewood for burning only. DO NOT use charcoal,

pressure treated lumber, sappy wood such as pine,

laminated wood or any material other than dry medium or

hard firewood.

DO NOT USE liquid fuel (firelighter fluid, gasoline, lantern

oil, kerosene or similar liquids) to start or maintain a fire.

Fire starters (smokeless, odorless, non-toxic lighter cubes)

are recommended.

Dispose of ashes using a metal shovel and place in a

metal bin with a tightly fitting lid. The container should be

stored on a non-combustible surface, away from all

combustible materials. Ensure ashes are completely cold

before disposing of them appropriately.

BEWARE of flying sparks from mouth of fireplace. Ensure

that no combustible materials are within range of fireplace

at any time.

DO NOT use water to dampen or extinguish fire in the

fireplace.

Contact your local building department for clarification on

any restrictions on installation of this fireplace in your area.

Maintenance

Have your chimney cleaned by a professional chimney

sweep if you have doubts about your ability to clean it.

Use a plastic, wood, or steel brush. If you have installed a

UL103 chimney system, do not use a brush that will

scratch the stainless steel liner of your chimney. Scrub the

spark arrestor with a wire brush.

Creosote – Formation and need for removal. When wood

is burned slowly, it produces tar and other organic vapors

that combine with expelled moisture to form creosote. The

creosote vapors condense in a relatively cook oven flue

and exhaust hood of a slow burning fire. As a result,

creosote residue accumulates on the flue lining and

exhaust hood. When ignited, this creosote makes an

extremely hot fire.

The oven flue should be inspected at least twice a year to

determine when creosote buildup has occurred.

When creosote has accumulated, it should be removed to

reduce risk of fire.



Appendix 1: Dimensions

27"22"

30"

10 1/2"21"

24"

9"

24"

20"

27"

10 1/2"21"

24"

9"

24"

20"12"

5"

12"

Calore2G7530" Modular Fireplace Kitv1.0, 09/10Copyright Forno Bravo, LLC 2010744 Neeson RoadMarina, CA 93933(800) 407-5119

3"

3"

15"

6"6"3"

38"

26"

5

8

10

11

1

11

11

11

2

3

1111

11

11

2

3

1

10

44

4

988

32 1/2"

38"

75"

51"

9 9

5 6

4

4

4

4

4"

22"

7 7 7



27"22"

36"

10 1/2"

31 1/2"

24"

9"

24"

20"

27"

10 1/2"

31 1/2"

24"

9"

24"

20"12"

5"

12"


3"

3"

15"

6"6"3"

44"

26"

2

5

8

10

11

1

11

11

11

2

3

1111

11

11

2

2

3

1

10

4

4

4

988

38 1/2"

44"

86"

62"

9 9

5 6

4

4

4

4

4

4

4"

22"

77 7



27"22"

42"

10 1/2"

31 1/2"

24"

9"

24"

22"

27"

10 1/2"

31 1/2"

24"

9"

24"

22"14"

5"

14"


3"

3"

15"

6"6"3"

50"

26"

2

5

8

10

11

1

11

11

11

2

3

1111

11

11

2

2

3

1

10

4

4

4

988

44 1/2"

50"

86"

62"

9 9

5 6

4

4

4

4

4

4

4"

22"

77 7



27"22"

48"

10 1/2"

31 1/2"

24"

9"

24"

22"

27"

10 1/2"

31 1/2"

24"

9"

24"

22"14"

5"

14"


3"

3"

15"

6"6"3"

56"

26"

2

5

8

10

11

1

11

11

11

2

3

1111

11

11

2

2

3

1

10

4

4

4

988

50 1/2"

56"

86"

62"

9 9

5 6

4

4

4

4

4

4

4"

22"

77 7



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